Mounting clips and sensor installations for motorized vehicle doors

ABSTRACT

Clips for attaching sensors, cables, or other items to doors, such as retrofitted armored vehicle doors, are provided. In one example embodiment, a clip includes a strip portion, a first attachment arm extending from the strip portion, and a second attachment arm extending from the strip portion. A barb leg is disposed at an angle relative to the strip portion and includes a first leg end and a second leg end opposite the first leg end. The barb leg is connected at the first leg end to the second attachment arm, and the second leg end is disposed towards and spaced apart from the strip portion. A cable clamp extends from an end of the second attachment arm opposite the strip portion or an end of the strip portion opposite the first attachment arm.

CROSS-REFERENCE TO RELATED APPLICATION

This application is a divisional of U.S. patent application Ser. No.12/197,058, filed Aug. 22, 2008 and titled MOUNTING CLIPS AND SENSORINSTALLATIONS FOR MOTORIZED VEHICLE DOORS, which is incorporated byreference in this application in its entirety.

FIELD OF THE INVENTION

This invention relates to sensors and sensor installation devices. Moreparticularly, the invention is related to a sensor and a clip that isused to install the sensor, such as around a perimeter of a motorizeddoor to detect obstructions between a closing door and a door frame.

BACKGROUND

To further protect military personnel during combat, military vehiclescan be provided with layers of armor. In some vehicles, the armor may beprovided on the vehicle in the factory during manufacture of thevehicle. However, it has become increasingly common for armor to beapplied to existing vehicles in the field.

The military started adding armor to various vehicles such as, forexample, its High Mobility Multipurpose Wheeled Vehicle, or “HMMWV” or“Humvee,” well before Operation Iraqi Freedom, but attacks from smallarms, rocket-propelled grenades and “improvised explosive devices,” orIEDs in military parlance, prompted the military to increase protectionfor vehicles already in the field. The “up-armored” HMMWV can weighthousands of pounds more than the standard HMMWV and includes severalhundred pound steel-plated doors. Such heavy armored doors make openingand closing the doors increasingly difficult for personnel.

In co-pending and commonly assigned U.S. patent application Ser. Nos.12/194,895 and 12/194,966, there is provided a mechanism for assistingin moving heavy armored doors on military vehicles. Such a mechanism canbe retrofitted to existing vehicles that are up-armored in the field. Topromote safety with such motorized door assist systems, sensors can bedesirably applied to ensure the door stops when an object or body partis in the way of door closing. There is a need for such a sensor systemthat can be applied to vehicle doors, and retrofitted to vehicles thatare up-armored in the field.

In particular, as many military vehicles were not designed in order tohave sensor parts attached thereto, there is a need for a sensor systemthat can be retrofitted to parts of vehicle doors that havemanufacturing variability, e.g., slightly misaligned parts from one doorto the next in the same type of vehicle. Misalignments in welded doorparts, albeit small and inconsequential to the structure and strength ofthe door, can present problems for parts designed to be attached tothese welded parts as the variations can cause fit problems.

SUMMARY

Clips for attaching sensors, cables, or other items to doors, such asretrofitted armored vehicle doors, are provided.

In one example embodiment, a clip includes a strip portion, a firstattachment arm extending from the strip portion, and a second attachmentarm extending from the strip portion. A barb leg is disposed at an anglerelative to the strip portion and includes a first leg end and a secondleg end opposite the first leg end. The barb leg is connected at thefirst leg end to the second attachment arm, and the second leg end isdisposed towards and spaced apart from the strip portion. A cable clampextends from an end of the second attachment arm opposite the stripportion or an end of the strip portion opposite the first attachmentarm.

In another example embodiment a clip includes a strip portion and afirst attachment arm and a second attachment arm each extending from thestrip portion. The strip portion is planar, and the first attachment armextends at a first end of the strip portion substantially perpendicularto the strip portion. The second attachment arm comprises a curvedportion that extends from the first end of the strip portion. A barb legis disposed at an angle relative to the strip portion and includes afirst leg end and a second leg end. The barb leg is connected at thefirst leg end to the second attachment arm. The second leg end isdisposed towards and spaced apart from the strip portion.

In another embodiment, a clip comprises a planar strip portion having afirst end and a second end opposite the first end. A countersunkmounting aperture is disposed through the strip portion for receiving afastener therethrough. The clip also includes two first attachment armsthat extend substantially perpendicular from a first end of the stripportion. A second attachment arm extends from the strip portion andincludes a curved portion that extends from the first end of the stripportion. The curved portion of the second attachment arm is disposedbetween the two first attachment arms. A barb leg is disposed at anangle relative to the strip portion and includes a first leg end and asecond leg end. The barb leg is connected to the second attachment armat the first leg end. The second leg end of the barb leg is disposedtowards and spaced apart from an area toward the second end of the stripportion.

In an additional embodiment, a clip includes a planar strip portionhaving a first end and a second end opposite the first end. A firstattachment arm extends from the first end of the strip portion. At leasttwo barb legs are disposed at an angle relative to the strip portion.Each of the barb legs includes a first leg end and a second leg end.Additionally, each of the barb legs is connected at the first end to thesecond attachment arm. The second leg end is disposed toward and spacedapart from an area toward the second end of the strip portion. A curvedcable clamp extends from an end of the second attachment arm oppositethe strip portion or from an end of the strip portion opposite the firstattachment arm.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 illustrates an exemplary vehicle door including a motorized doorassist system.

FIGS. 2 and 3 illustrate a safety switch according to one exampleembodiment.

FIGS. 4A-C illustrate a clip according to one example embodiment.

FIGS. 5A-C illustrate a clip according to another example embodiment.

FIGS. 6A-C illustrate a clip according to another example embodiment.

FIGS. 7A-C illustrate a clip according to yet another exampleembodiment.

FIG. 8 illustrates a clip and mounting bracket combination according toone example embodiment.

FIGS. 9-11 illustrate one example of a sensor switch applied to avehicle door by clips.

DETAILED DESCRIPTION

A clip for securing one object relative to another, such as securing anobject to a vehicle door or frame is provided. In one embodiment, theclip is used to retrofit a vehicle door with a strip of safety sensors,and, more particularly, may retrofit vehicle doors that are notoriginally intended to be retrofitted in this way. Co-pending patentapplication Ser. Nos. 12/194,895 and 12/194,966 provide an apparatus forassisting in moving heavy armored doors on military vehicles. Such anapparatus can be retrofitted to existing vehicles that are up-armored inthe field. To promote safety with such motorized door assist systems,sensors can be applied to ensure the door stops when an object or bodypart is in the way of door closing. FIG. 1 is an example armored vehicledoor as described in the co-pending patent application Ser. Nos.12/194,895 and 12/194,966, entitled “Door Assist System and Method ForRetrofit Installation of Apparatus” and “Door Assist System Controllerand Method” respectively, herein incorporated by reference.

The door 20 of FIG. 1 includes a safety sensor, referred to herein assafety switch 22. The safety switch 22 activates should the automateddoor 20 be closing and any part of the switch 22 is depressed. Whendepressed the switch 22 will cause the moving door 20 to immediatelycease and, optionally, open a small amount. This safety mechanism isintended to prevent door closures while obstructions remain between thedoor and the door frame. The safety switch 22, which is connected to acontrol box 21, can include one or more sensors 24 strategically placedaround at least portions of the outside perimeter of the door. In oneembodiment, the safety switch 22 includes a multi-segmented, largesurface area, single pole switch, as generally illustrated in FIGS. 2and 3, that is located around at least portions of the inside perimeterof the door.

The safety switch 22 of FIG. 2 includes a plurality of sensors 24connected by electrical connectors, e.g., wires or cables 26. Eachsensor 24 includes a touch-sensitive sensing element 28 (e.g., astainless steel electrode) molded in a semi-circular polymer casing 30.The cables 26 can also be enclosed by the polymer casing 30, which canbe formed of various deformable polymer materials, such as rubber orpolyurethane. The length and spacing of the individual sensors 24, andthus the length of the intermediate cables 26, are dependent on the needof the installation. In one example, the safety switch may be a modifiedversion of the SENSI-SWITCH available from Recora (Batavia, Ill.), butthe safety switch is not intended to be limited to any particular size,shape, sensor type, or materials of formation.

In one embodiment, as shown in FIG. 3, the semi-circular sensor 24 canbe secured to a surface by a mounting bracket 32. The mounting bracket32 can be a metal or plastic mounting bracket that is in turn attachedto the vehicle door, such as using the clips discussed below. The sensor24 can be held in the mounting bracket 32 by any suitable means, such asan adhesive, double sided adhesive tape, or by being secured by angledbracket arms 34. The sensor 24 can, for example, clip into or slide infrom an end of the bracket 32, and be held by the angled bracket arms34. The sensors 24, for example, may include molded-in threaded nuts orother fasteners for use in attaching to the clip or bracket.

As discussed above, the Humvee vehicle doors are commonly retrofittedwith heavy armor in the field. Thus the motorized door system and safetysensors discussed above are also desirably retrofitted to existingdoors. As it is generally undesirable to drill into the armored doors,the present invention provides clips for attaching the safety strips tothe vehicle doors. FIGS. 4A-C through 7A-C illustrate particularembodiments of clips useful to apply the safety strip. The clips may bedesigned to attach to “L” or “I”-shaped flanges of any vehicle, therebyallowing the sensor system to be retrofitted to any type of vehicle doorwithout the need for drilling or a special tool. FIGS. 9-11 illustrateembodiments of the clips attaching a safety switch sensor to a vehicledoor.

FIGS. 4A-C illustrate a clip 40 according to one embodiment. The clip 40included a strip portion 42 to which the safety switch or a mountingbracket can be attached. As shown in FIGS. 4A-B, the strip portion 42can include one or more countersunk mounting apertures 44. Fasteners canextend through the mounting apertures 44 for connecting a mountingbracket to the strip portion 42.

A first attachment arm 46 extends at an angle, more particularlysubstantially perpendicular, from the generally planar strip portion 42.In the example shown in FIGS. 4A-C, an attachment tab 48 extends at anangle from an end 49 of the first attachment arm 46 that is opposite asecond end 50 of the first attachment arm 46 that is connected to thestrip portion 42. As shown in FIG. 4C, the first attachment arm 46 andthe attachment tab 48 secure over one end of an “L”-shaped portion,e.g., flange 45, of a vehicle door. The attachment tab 48 is desirablycurved to facilitate attachment to the flange 45. The properties of theclip material and the dimensioning of the first attachment arm 46 andtab 48 allow for a gripping force on the thickness of the flange 45, andthe curved tab 48 allows the clip 40 to be easily installed over the topof the flange.

A second attachment arm 54 extends at an angle, more particularlysubstantially perpendicular in FIGS. 4A-C, from an opposite end of thestrip portion 42 from the first attachment arm 46. Thus, the secondattachment arm 54 is substantially parallel to the first attachment arm46. As shown in FIG. 4C, the second attachment arm 54 secures around anopposite end of the flange 45 from the first attachment arm 46. Thesecond attachment arm 54 can optionally include an angled end portion 56for facilitating attachment to the flange 45.

The clip 40 includes two barb legs 60 disposed at an angle relative thestrip portion 42. The barb legs 60 each include a first leg end 62 and asecond leg end 64 opposite the first leg end 62. Each of the barb legs60 is connected at the first leg end 62 to the second attachment arm 54,and the second leg end 64 is disposed toward and spaced apart from thestrip portion 42. The second leg end 64 is desirably bent toward thedirection of the first attachment arm 46 and the flange 45, and, asshown in FIG. 4C, assists in securely holding the clip 40 on the flange45. The clip 40 optionally includes a recess space 66 disposed adjacentto a side end 68 of each of the barb legs 60. The recess spaces 66,which separate the barb leg side ends 68 from the second attachment arm54, can be used for facilitating removal of the clip 40 with a tool suchas a screwdriver. Furthermore, the placement of the barb legs 60 towardthe outer side edges of the clip 40 also facilitates removal of the clip40.

As shown in FIG. 4C, the flange 45 is formed of a horizontal portion anda vertical portion. In the example of the clip 40 shown, the barb legs60 are designed to contact the bottom surface of the vertical portion ofthe flange. This can be particularly beneficial when the flange 45 isformed from the vertical portion being welded to the horizontal portion.It is common that the welded connection of the horizontal and verticalportions is not flush. By having the barb legs 60 contact the verticalportion, the clip 40 is assured a secured fit even when the flangecomponents are misaligned. Also, the vertical portion of the flange 45is often composed of several sections around the door horizontal flange,and having multiple clips attached to a single bracket which may spanmore than one vertical portion, any misalignment in the verticalportions can be better accommodated. In this manner, the clips andsafety sensor may allow for retrofitting vehicle doors that were notintended to be retrofitted in this way.

As will be appreciated by those skilled in the art following theteachings herein provided, various sizes, shapes, and configurations areavailable for the clip depending on need, such as depending on theconfiguration of the vehicle door. Further, various and alternativematerials can be used to form the clip. In one example, the clips may beformed at least in part from spring steel.

FIGS. 5A-C illustrate a clip 70 according to another embodiment, whichis a variation of the clip in FIGS. 4A-C. Clip 70 includes a stripportion 72, a first attachment arm 74 and a second attachment arm 76 asdiscussed above, and which function as discussed above. Clip 70 differsfrom clip 40 discussed above, by including a curved cable clamp 80extending from an end 82 of a second attachment arm 76 that is oppositethe strip portion 72. The cable clamp 80 is particularly useful forholding electrical connectors (i.e., electrical connection devices orelectrical conductors), such as a cable 26 of the safety switch 22 shownin FIG. 2.

The clip 70 can be used in combination with the clip 40 to secure, forexample, the safety switch 22 to a vehicle door such as shown in FIG. 1.The clip 40 can be used to secure the sensor 24 portion of the safetyswitch 22, and the clip 70 can be used to secure the cable 26. In theexample shown in FIGS. 5A-C, the clip 70 does not include any optionalcountersunk mounting aperture, as this clip 70 is designed for securingthe cable 26. However, clip 70 can include one or more countersunkapertures if a single, dual-purpose clip is desired.

FIGS. 6A-C illustrate a clip 90 according to yet another exampleembodiment. Whereas the clips 40 and 70 discussed above are designed fora bent or “L”-shaped flange, such as shown in FIG. 4C, the clip 90 isdesigned for a straight or “I”-shaped door lip or flange, such as shownin FIG. 6C.

Clip 90 includes a substantially planar strip portion 92 including acountersunk mounting aperture 94 for receiving a fastener therethrough.The clip 90 includes two first attachment arms 96 extending at an angle(e.g., substantially perpendicular) from the strip portion 92 at a firstend 98 of the strip portion 92. A second attachment arm 100 also extendsfrom the first end 98 of the strip portion 92. The second attachment arm100 includes a curved portion 102 extending from the first end 98 of thestrip portion 92. The curved portion 102 is disposed between the twofirst attachment arms 96. The two first attachment arms 96 provide forproper alignment of the sensor or cable around the flange 115 as theylimits the depth to which the flange 115 penetrates into the clip 90.Incorrect placement of the clip 90 on the flange can result in thesafety switches being rendered inoperable due to incorrect placementand/or the cable being disposed in a pinch point of the door perimeter.

The clip 90 includes two barb legs 106 disposed at an end 105 of thesecond attachment arm 100 that is opposite the strip portion 92. Each ofthe barb legs 106 is disposed at an angle relative the strip portion 92.Each of the barb legs includes a first leg end 108 and a second leg end110 that is opposite the first leg end 108. Each barb leg 106 isconnected at the first leg end 108 to the second attachment arm 100 andthe second leg end 110 is disposed or pointed toward and spaced apartfrom the strip portion 92. In the embodiment shown in FIGS. 6A-C, thesecond attachment arm 100 includes a curved end portion 112, from whichthe barb legs are cut or stamped. A recess 114 is optionally formedbetween a side edge 116 of each barb leg 106 and a portion of the secondattachment arm 100.

FIGS. 7A-C illustrate a clip 120 according to another exampleembodiment, which is a variation of the clip in FIGS. 6A-C. Clip 120includes a strip portion 122, two first attachment arms 124 and a secondattachment arm 126 as discussed above for FIGS. 6A-C. Clip 120 differsfrom clip 90 discussed above, by including a curved cable clamp 130extending from an end 132 of a strip portion 122 that is opposite thefirst and second attachment arms 124 and 126. The cable clamp 130 isparticularly useful for holding electrical connectors, such as a cable26 of the safety switch 22 shown in FIG. 2. The clip 120 can also beused in a same or similar manner to the clip 70 discussed above, such assecuring the cable 26 to a vehicle door. The clip 120 could include theoptional countersunk mounting apertures, if a single, dual-purpose clipis desired. As will be appreciated by those skilled in the art followingthe teachings herein provided, various and alternative sizes, shapes andconfigurations are available for the clips 90 and 120 as seen. Forexample, the cable clamp can optionally extend from the end of thesecond attachment arm (as illustrated in phantom in FIG. 7C) that isopposite the strip portion, thereby providing a planar surface on oneside of the clip 120 for use in tight spaces.

The example clips provided are particularly useful in a method ofretrofitting a vehicle door to include sensors such as the safety switchdiscussed herein. Each clip is selected for and applied to a particularlocation of the door. The first attachment arm of each clip is placedover a door flange of the vehicle door and the clip is pressed into aposition where the second leg end of the barb leg is adjacent the doorflange, such as shown in FIGS. 4C and 6C. The safety switch is securedto the clip, optionally by attaching the intermediate mounting bracket,either before or after the clip is attached to the vehicle.

In one embodiment, the sensor 24 of the safety switch 22 may beconnected to the clip by amounting bracket, such as mounting bracket 32discussed above. FIG. 8 illustrates an example embodiment in which amounting bracket 32 is fastened to a clip. In FIG. 8, clip 40 is usedfor illustration, but it will be appreciated that any other example clipas seen herein can be used in a same or similar manner.

Fasteners 134 (e.g., rivets, screw, bolts, etc.) extend through thecountersunk apertures 44 to connect the clip 40 to an optional spacerbracket 140. The spacer bracket 140 is similarly connected by fasteners(e.g., rivets, screw, bolts, etc.) to the mounting bracket 32. Attachingthe mounting bracket 32 to the clip 40 before applying the clip to thedoor can desirably facilitate connection of the bracket 32 to the clip40. The bracket 32, which will likely include more than one clip 40, canbe easily attached by clipping the attached clips over a door flange inthe manner discussed above.

FIGS. 9-11 illustrate the sensor switch applied to a vehicle door. FIGS.9 and 10 illustrate the attachment of the clip and mounting bracketcombination of FIG. 8 to an “L”-shaped flange 145 of a vehicle door 150.As discussed above, the flange is formed of a first portion 146 weldedto a second portion 148. In the embodiment of the clip 40 shown, thebarb legs 60 are designed to contact the bottom surface of the firstportion 146 of the flange 145. As mentioned above, by having the barblegs 60 contact the first portion 146, the clip 40 is assured a securedfit even when the flange components 146 and 148 are slightly misaligned.In FIGS. 9 and 10, a sensor 24 is shown mounted in the mounting bracket32.

FIG. 11 illustrates the clip 90 attached to an “I”-shaped flange 165 ofa door 160. The clip 90 is attached to a spacer bracket 162, whichallows for attachment of the mounting bracket 32 at a ninety-degreeangle to the flange 165. In this embodiment, one type of mountingbracket can be used for both “I”-shaped and “L”-shaped flanges. As willbe appreciated by those skilled in the art following the teachingsherein provided, the mounting bracket 32 can be designed to attachdirectly to the clip or the mounting bracket can otherwise be configuredto make the use of the spacer bracket 162 unnecessary.

Thus a clip and a mountable safety sensor strip are provided forretrofitting, for example, an up-armored military vehicle having amotorized door assist system. The clips, as seen, are easily mounted toportions of the door or vehicle frame during sensor installation.

The invention illustratively disclosed herein suitably may be practicedin the absence of any element, part, step, component, or ingredientwhich is not specifically disclosed herein.

While in the foregoing detailed description this invention has beendescribed in relation to certain preferred embodiments thereof, and manydetails have been set forth for purposes of illustration, it will beapparent to those skilled in the art that the invention is susceptibleto additional embodiments and that certain of the details describedherein can be varied considerably without departing from the basicprinciples of the invention.

1. A clip comprising: a strip portion; a first attachment arm extendingfrom the strip portion; a second attachment arm extending from the stripportion; a barb leg disposed at an angle relative to the strip portionand including a first leg end and a second leg end opposite the firstleg end, the barb leg connected at the first leg end to the secondattachment arm and the second leg end is disposed toward and spacedapart from the strip portion; and a cable clamp extending from an end ofthe second attachment arm opposite the strip portion or an end of thestrip portion opposite the first attachment arm.
 2. A clip comprising: astrip portion; a first attachment arm extending from the strip portion,wherein the strip portion is planar and the first attachment arm extendsat a first end of the strip portion substantially perpendicular to thestrip portion; a second attachment arm extending from the strip portion,wherein the second attachment arm comprises a curved portion extendingfrom the first end of the strip portion; a barb leg disposed at an anglerelative to the strip portion and including a first leg end and a secondleg end, the barb leg connected at the first leg end to the secondattachment arm and the second leg end is disposed toward and spacedapart from the strip portion.
 3. The clip according to claim 2, furthercomprising two first attachment all ns, and the curved portion of thesecond attachment arm is disposed between the two first attachment arms.4. The clip according to claim 2, wherein the barb leg is disposed at anend of the second attachment arm opposite the strip portion.
 5. A clipcomprising: a planar strip portion including a first end and a secondend opposite the first end; a countersunk mounting aperture disposedthrough the strip portion for receiving a fastener therethrough; twofirst attachment arms extending substantially perpendicular from a firstend of the strip portion; a second attachment arm extending from thestrip portion, the second attachment arm including a curved portionextending from the first end of the strip portion, the curved portion ofthe second attachment arm disposed between the two first attachmentarms; and a barb leg disposed at an angle relative to the strip portion,the barb leg including a first leg end and a second leg end, the barbleg connected at the first leg end to the second attachment arm and thesecond leg end is disposed toward and spaced apart from an area towardthe second end of the strip portion.
 6. The clip according to claim 5,wherein the barb leg is disposed at an end of the second attachment armopposite the strip portion.
 7. The clip according to claim 5, furthercomprising a plurality of barb legs disposed at an angle relative to thestrip portion.
 8. A clip comprising: a planar strip portion including afirst end and a second end opposite the first end; a first attachmentarm extending from the first end of the strip portion; a plurality ofbarb legs disposed at an angle relative the strip portion and each ofthe barb legs including a first leg end and a second leg end, each ofthe barb legs connected at the first end to the second attachment armand the second leg end is disposed toward and spaced apart from an areatoward the second end of the strip portion; and a curved cable clampextending from an end of the second attachment arm opposite the stripportion or from an end of the strip portion opposite the firstattachment arm.
 9. The clip according to claim 8 further comprising: twofirst attachment arms; and the second attachment arm including a curvedportion extending from the first end of the strip portion, the curvedportion of the second attachment arm disposed between the two firstattachment arms.